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TPM & Industry 4.0

November 30th

2016

Presentation by Prof. Dr. Constantin May

Centre of Excellence for TPM at Ansbach University of Applied Sciences

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Agenda

Introduction of the Centre of Excellence for TPM (CETPM)

8 Pillars of TPM / the TPM House

Changing Business Enviroment

Introduction to Industry 4.0

Some Examples from German Industry

TPM and Industry 4.0

Challenges of Industry 4.0

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Ansbach University of Applied Sciences

■ Located close to Nuremberg on the premises of a former Ansbach US barracks

■ Ansbach University was founded in 1996. Today it has 3150 students.

■ 14 Bachelor programs, 4 Master programs, 2 extra occupational Bachelor programs

■ Business Administration, Plastics Technology, Energy and Environmental Technology,

Bio medical technology etc. …

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The CETPM Institute at Ansbach University/ Herrieden Campus

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Small but smart!

How can we avoid pictures like this?

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We

teach and train people.

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We help with books and the Yokoten Magazin

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8 Pillars of TPM and the TPM House

Social Satisfaction

Shareholder Satisfaction Employee Satisfaction

Environmental Satisfaction

Customer Satisfaction

P Q C D S M

Focused

Improvem

ent

and

Lean M

anagem

ent

Autonom

ous

Main

tenance

Pla

nned

Main

tenance

Train

ing and

Educatio

n

Early

Equip

ment M

anagem

ent

Quality M

ain

tenance

Off

ice T

PM

Safe

ty, H

ealth,

Envir

onm

ent

Management Commitment

Pol icy Deployment Process

Leadership focused on Employee Development

Experimental Learning with PDCA

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Our world is changing faster than ever

Volatile Markets

Uncertain

replenishment

lead times

SOURCE

Shorter Product Livecycles

Increasing Product

Complexity and

Smaller Lot Sizes

MAKE

Volatile Markets

Individualized Products

Shorter Delivery Times

DELIVER

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Product Life Cycle of the Volkswagen Golf

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“History” of Industry 4.0

The term "Industrie 4.0" originates from a project in the

high-tech strategy of the German government.

See Video:

https://youtu.be/GKhSTjraHlU

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“History” of Industry 4.0

4.0 refers to the “Fourth Industrial Revolution”.

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Vision of Industry 4.0

Internet of Things Internet of Services

Internet of People

Cyber-physical

Systems

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Vision of Industry 4.0

For a factory to be considered Industry 4.0, it must include:

Interoperability — machines, devices, sensors and people that

connect and communicate with one another.

Information transparency — the systems create a virtual copy of the

physical world through sensor data (digital shadow).

Technical assistance — both the ability of the systems to support

humans in making decisions and solving problems and the ability to

assist humans with tasks that are too difficult or unsafe for humans.

Decentralized decision-making — the ability of cyber-physical

systems to make simple decisions on their own and become as

autonomous as possible.

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" This particularly sleekly carfrom 1975 is an elegant two-seaterwith Nuclear Rear-Drive; the seatsare located right behind the front

wheels. . . "

VISIONS – A difficult task

It´s the Year

1955...

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Agenda

Industry 4.0

A Revolution?

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Agenda

or…

…old wine in

new bottles?

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Examples from German Industry (Bosch)

See Video:

https://youtu.be/GKhSTjraHlU

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Examples from German Industry (Volkswagen)

See Video:

https://youtu.be/JTl8w6yAjds

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Maintenance Staff of the Future?

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TPM in a Smart Factory

Industry 4.0 open doors to new and enriching maintenance possibilities:

Sensors help to identify failures of machines or components earlier

and allows machines to autonomously ask operators (e.g. via mobile

devices) to perform maintenance tasks.

Integrated condition monitoring capabilities and big data analytics

enable auto-diagnostics and supports conditions based and predictive

maintenance.

Technical assistance

(e.g. collaborative robots)

helps to carry out

maintenance task.

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Vision of a Cloud based Maintenance Approach…

Source: http://www.imain-project.eu

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Big Challenges of Industry 4.0

A high degree of reliability and stability are needed for successful cyber-physical

communication that can be difficult to achieve and maintain.

Due to shorter lifecylcles automation has to be low cost

Data security issues are greatly increased by integrating access to the internet.

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Need for low cost flexible automation

Standard ExoticsExotics

Quantity / Unit Cost

Actual Cost

Target Cost

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The JIPM Solution

Karakuri Kaizen®

TPM and Karakuri Kaizen are registred trademarks of JIPM

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Karakuri Kaizen®

Karakuri Kaizen®

means simple and low cost automation using

intelligence of the operators. It is the perfect companion for automation

using collaborative robots. This is how we teach it…

2004

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The transformation can only be accomplished

by man, not by hardware

(computers, gadgets, automation, new machinery).

A company can not buy its way into quality.

W. Edward Deming, Out of the Crisis, p.11

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